NUMERICAL SIMULATION OF CASTING'S MOLD FILLING PROCESS

Numerical simulation of casting＇s mold filling process is the main and the most important aspect of the foundry CAE technology. But it is time-consuming; it may take dozens of hours or several days. While with the development of computer hardware, numerical simulation of casting＇ s mold filling process has made rapid progress. The simulation results, therefore, have become more and more practical. This study tries to find some clues of the computational time of mold filling process. Firstly, this paper introduces mathematic model and the basic route of numerical simulation of casting＇s mold filling process. Then the computational time of mold filling process has been carefully studied, and some new and useful results have been gained from the study of the computational time. Finally, this paper has given some real applications of numerical simulation of casting＇s mold filling process.

Optimization of clay material mixture ratio and filling process in gypsum mine goaf

Because there is neither waste rock nor mill tailings in the gypsum mine, and the buildings on the goaf of gypsum mine are needed to be protected, the research proposed the scheme of the clay filling technology. Gypsum, cement, lime and water glass were used as adhesive, and the strength of different material ratios were investigated in this study. The influence factors of clay strength were obtained in the order of cement, gypsum, water glass and lime. The results show that the cement content is the determinant influence factor, and gypsum has positive effects, while the water glass can enhance both clay strength and the fluidity of the filing slurry. Furthermore, combining chaotic optimization method with neural network, the optimal ratio of composite cementing agent was obtained. The results show that the optimal ratio of water glass, cement, lime and clay (in quality) is 1.17:6.74:4.17:87.92 in the process of bottom self-flow filling, while the optimal ratio is 1.78:9.58:4.71:83.93 for roof-contacted filling. A novel filling process to fill in gypsum mine goaf with clay is established. The engineering practice shows that the filling cost is low, thus, notable economic benefit is achieved.

Basin-filling processes and hydrocarbon source rock prediction of low-exploration degree areas in rift lacustrine basins:a case from the Wenchang Formation in low-exploration degree areas,northern Zhu I Depression,Pearl River Mouth Basin,E China

Hydrocarbon source rocks, as a main geologic factor of petroliferous systems in a sedimentary basin, play a key role in the accumulation of oil and gas and the formation of hydrocarbon accumulations. This study, which focuses on difficulties in prediction of hydrocarbon source rocks in basins or sags with low exploration degree and insufficient hydrocarbon source rock indicators, taking the Wenchang Formation of northern Zhu I Depression, Pearl River Mouth Basin as an example, proposed a hypothesis of “finding lakes and hydrocarbon source rocks”. Detailed steps include, first, determination of the lacustrine basin boundary according to analysis of seismic foreset facies, determination of the depositional area based on the compilation of strata residual thickness maps, determination of the lacustrine basin shape according to deciphering slope break belt system, determination of the fluctuation of paleo-water depth according to biogeochemical indicators of mature exploration areas, determination of the lacustrine basin scale based on analyses of tectonics intensity and accommodation space, which prove the existence of the lacustrine basin and identify the range of semi deep-deep lake;second, further analyses of tectonopalaeogeomorphology, paleo-provenance,palaeoclimate and paleo-water depth to reconstruct the geologic background of the original basin and semideep-deep lacustrine facies, to determine the distribution of semi-deep/deep lacustrine sediments in combination with studies of logging facies, core facies, seismic facies and sedimentary facies, and to rank the sags’ potential of developing hydrocarbon source rocks from controlling factors of source-to-sink system development;third, on the basis of regional sedimentary facies analysis, through identification and assessment of seismic facies types of semi-deep/deep lacustrine basins in mature areas, establishing “hydrocarbon source rock facies” in mature areas to instruct the identification and depicting of hydrocarbon source rocks in semideep/deep lacustrine basins with low exploration degree;fourth, through systematical summary of hydrocarbon-rich geological factors and lower limit index of hydrocarbon formation of the sags already revealed by drilling wells(e.g., sag area, tectonic subsidence amount, accommodation space, provenance characteristic, mudstone thickness, water body environment, sedimentary facies types of hydrocarbon source rocks), in correlation with corresponding indexes of sags with low exploration degree, then the evaluation and sorting of high-quality source rocks in areas with sparsely distributed or no drilling wells can be conducted with multi-factors and multiple dimensions. It is concluded that LF22 sag, HZ10 sag and HZ8 sag are II-order hydrocarbon rich sags;whereas HZS, HZ11 and HZ24 are the III-order hydrocarbon-generating sags.

Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

ANALYTICAL SOLUTION OF FILLING AND EXHAUSTING PROCESS IN PNEUMATIC SYSTEM

The filling and exhausting processes in a pneumatic system are involved with many factors, and numerical solutions of many partial differential equations are always adapted in the study of those processes, which have been proved to be troublesome and less intuitive. Analytical solutions based on loss-less tube model and average friction tube model are found respectively by using fluid net theory, and they fit the experimental results well. The research work shows that： Fluid net theory can be used to solve the analytical solution of filling and exhausting processes of pneumatic system, and the result of loss-less tube model is close to that of average friction model, so loss-less tube model is recommended since it is simpler, and the difference between filling time and exhausting time is determined by initial and final pressures, the volume of container and the section area of tube, and has nothing to do with the length of the tube.

Raw Gangue Filling Mining under Construction —A Case Study in China

In order to recover the strip pillar coal resources, reduce the amount of gangue mountain and realize remediation of the goaf environment in the old mining area, the raw gangue filling mining technology was proposed. According to the previous practical experience, the feasibility of the implementation of raw gangue filling mining technology in the coal-pressed area was analyzed. Through the filling gangue compaction test, the deformation under different loading stages was obtained. Further, a reasonable prediction of the deformation beyond the experimental limited loading load was made based on the experimental results. Through the deformation source analysis of the whole process of gangue filling, the key factors for controlling deformation before, during, and after filling were determined. Additionally, the proportion of deformation during different stages was quantified. Considering the protection of surface buildings, mining fullness of the working face and mining technology, the production parameters of 1209 and 1210 filling working faces were preliminarily determined. Through numerical simulation, the rationality of mining scheme was verified. Based on the practice of 1209 working face and the key factors to control the deformation of gangue filling, the mining system and process in 1210 working face were optimized. According to the measured surface rock movement, raw gangue filling mining technology can meet the requirements of surface building protection level. Especially, this paper provides a method to quantitatively calculate the equivalent mining height (EMH) of raw gangue filling and its mining deformation, which has reference significance for old mining areas.

Effects of mechanical vibration on filling and solidification behavior, microstructure and performance of Al/Mg bimetal by lost foam compound casting

Al/Mg bimetal was prepared by lost foam solid-liquid compound casting,and the effects of mechanical vibration on the filling and solidification behavior,microstructure and performance of the bimetal were investigated.Results show that the mechanical vibration has a remarkable influence on the filling and solidification processes.It is found that after mechanical vibration,the filling rate increases and the filling rate at different times is more uniform than that without vibration.In addition,the mechanical vibration also increases the wettability between liquid AZ91D and A356 inlays.The mechanical vibration reduces the horizontal and vertical temperature gradient of the casting and makes the temperature distribution of the whole casting more uniform.Compared to the Al/Mg bimetal without vibration,the shear strength is improved by 39.76%after the mechanical vibration is applied,due to the decrease of the inclusions and Al_(12)Mg_(17) dendrites,and the refinement and uniform distribution of the Mg_(2)Si particles in the interface of the Al/Mg bimetal.